1963 Mercury 500 50hp

[bgc]

Re: 1963 Mercury 500 50hp

I have "Link and Sync'ed". The fly wheel has a mark for the .235" BTDC and the points open at this time when cranking while holding full advance.

I have tried a couple times to adjust the idle for the carbs. It coughs so much its hard to determine where the setting should be. The hole shot seems to work where ever I have the carbs set

 

[bgc]

Re: 1963 Mercury 500 50hp

This motor has been a joy for the past two summers but something is still not right. So now I'm going to tear everything down.

On the list is;
New rings
New gaskets
Upper and lower crank bearings
Upper and lower crank seals
Needle bearings
New paint
and Reworking the lower unit.

 

[bgc]

Re: 1963 Mercury 500 50hp

The powerhead came off the midsection today. Took about three hours to strip everything.

If you haven't tried KROIL, Its worth the money. I applied it a couple days ago and everything came apart smoothly..... I haven't tried the exhaust bolts yet, going to give them a week.

UPDATE. All of the bolts came out with with a 1/4" drive ratchet. KROIL has been the best penetrating oil I have found.

 

[bgc]

Re: 1963 Mercury 500 50hp

Ultrasonic cleaner with hot water and Pine-sol makes quick work of cleaning carbs.

 

[bgc]

Re: 1963 Mercury 500 50hp

I separated the block today and found the #1 piston is scored.... There is also a thick carbon build up on the exhaust side.

​

 

[bgc]

Re: 1963 Mercury 500 50hp

Mike at Outboard Paradise had all the wrist pin, crank and main bearings for this motor. He also found 4 pistons for me.

http://stores.intuitwebsites.com/OutboardParadise/StoreFront.bok

 

[bgc]

Re: 1963 Mercury 500 50hp

New pistons with crank, wrist, upper and lower bearings.

 

[bgc]

Re: 1963 Mercury 500 50hp

Did some more work.... Mercury 500 50hp 1963 8/22/2011 - YouTube

Coming off a plane to idle, it runs smooth for about 30 seconds and then starts coughing. It will continue to cough and sputter through mid throttle when accelerating. I have now cleaned all the passages with a bit and vice, could there be too much fuel during idle?

Found the upper and lower seals are shot. This was allowing air to enter the case leaning out the fuel mixture. Also allowed water into the #4 cylinder.

 

[bgc]

Re: 1963 Mercury 500 50hp

Pistons and new bearings are on the crank.

 

[Aqualift]

Re: 1963 Mercury 500 50hp

Nice update and pics! It looks like your making good progress with this more thorough rebuild. It will be interesting to see how it performs after this work is completed.

In addition to my 65 Merc 500, I just got a 68 Merc 500 up and running with minimal repairs. There are a few issues with both of them, so it's interesting to follow your tear down. I might do a complete rebuild in the future of both my Mercs.

 

[bgc]

Re: 1963 Mercury 500 50hp

Aqualift,
Its surprisingly easy to do.

 

[Aqualift]

Re: 1963 Mercury 500 50hp

On the 68, I removed the powerhead and cleaned out clogged water jacket passageways. Also, I replaced the exhaust cover and baffle plate gaskets along with the powerhead/exhaust base plate gasket. So I guess I was halfway there....

Only issue I ran into were severely corroded bolts on the exhaust cover plate. Even with heat and PB blaster, 3 broke. I had to drill them out and retap. Did you run into any stuck bolts? My baffle plate had severe corrosion. I think this Merc was run in saltwater with all the sand and corrosion I found. I just reread the post where you mentioned the update on the bolts. I guess you didn't break any and that Kano Kroil works.

I notice I have a leaky upper end cap seal. Probably the o-ring. Any leak would cause rough running.

Did you take compression readings pre-rebuild? I'm curious how much better the compression will be with those new pistons and rings?

 

[bgc]

Re: 1963 Mercury 500 50hp

KROIL, I put it on every bolt and up the exhaust then let it sit for a week. Not one bolt broke and I removed each with a 1/4" drive ratchet.

I did not do a compression test until I started the tear down. The engine was heavily fogged when I did do it,giving false readings.

 

[bgc]

Re: 1963 Mercury 500 50hp

Did the upper and lower end caps, baked at 170 degrees for 15 minutes and the bearings popped out.

 

[bgc]

Re: 1963 Mercury 500 50hp

Set the pistons without ring compressors (I will be buying some for the next motor). I cut strips of aluminum, compressed the rings by hand, wrapped the strips around the rings and taped in place.

 

[bgc]

Re: 1963 Mercury 500 50hp

I have spent some time rolling the crank by hand watching the wear on the rings and am satisfied with the pattern. All of the black oxide on the faces has worn away (heavily oiled with two stroke).
I sealed up the block with Loctite 518 and activator. Installed the new gaskets and related components. Now prepping for paint, I cant wait to fire this engine up and get the boat finished.

 

[bgc]

Re: 1963 Mercury 500 50hp

I have been working on rebuilding the lower unit over the past two days. According to the Mercury Manual " Use the reverse gear puller to remove the reverse gear" then, "Press the bearing out of the carrier".
Well Murphy stepped in and the bearing stayed on the reverse gear. I used a bearing splitter and a press to separate the two with out damaging the thrust washer that sits between them. The bearing splitter was only there to support the bearing and not squeezing on it.

 

[bgc]

Re: 1963 Mercury 500 50hp

Been working on getting ready for painting. Patched dents and dings with JB Weld.

 

[bgc]

Re: 1963 Mercury 500 50hp

Got the base coats of paint on today. Ordered from, Reproptint Paints & EffenA Co Online Store - Home

 

[bgc]

Re: 1963 Mercury 500 50hp